Production order number-based process plan intelligent filtering and completion rate calculation method

Abstract

The invention relates to the technical field of commercial data processing, and discloses a production order number-based process plan intelligent filtering and completion rate calculation method, which comprises a plurality of steps of obtaining a to-be-produced quantity, obtaining a raw material quantity, setting a standard threshold value, comparing the threshold values, making different coping strategies according to a comparison result and the like. According to the method, the number of the to-be-produced products is obtained through the order numbers, the number of the needed raw materials is reflected through the number of the to-be-produced products, the qualified products actually produced under the number of the raw materials are obtained, and the ratio of the actually produced qualified products to the number of the to-be-produced products reflects the actual completion rate. The completion rate obtained by the method is more accurate than the completion rate obtained based on the process.

Description

Technical Field

[0001] The present invention relates to the technical field of commercial data processing, and in particular to a method for intelligent filtering of process plans and calculation of completion rates based on production order numbers. Background Art

[0002] The production order number is a code or digital sequence used by enterprises to uniquely identify each production order in production management. It usually contains some specific information to facilitate the management, tracking and recording of the production process.

[0003] The production process is the core link in production management, involving the entire conversion process from raw materials to finished products. Reasonable design, effective management and continuous optimization of production processes can significantly improve production efficiency and product quality, helping enterprises maintain their advantages in competition.

[0004] There is an inseparable relationship between production orders and production processes. In some production environments, the number of production processes is used to determine the completion rate of production orders. For example, in a production order, there are ten products that need to be produced, and each product needs to go through ten processes to be completed. The total number of production processes is 100, and the completion rate can be determined based on the total number of completed processes. However, this only applies to single-model products, and different models of products may require different processes. For example, for a wok in kitchenware, a wok with a front handle has one less process than one without a front handle, so the completion rate cannot be determined by the total number of completed processes. In addition, the completion of the process is difficult to represent the completion rate. Because it may be that one product is missing so many processes, or it may be that many products are missing processes. Summary of the invention

[0005] In view of the problems existing in the above-mentioned prior art, the purpose of the present invention is to provide a method for intelligent filtering of process plans and calculation of completion rates based on production order numbers, so as to be able to judge the product completion rate.

[0006] In order to achieve the above-mentioned purpose, the present invention provides the following technical solution: a method for intelligent filtering of process plans and calculation of completion rate based on production order numbers, comprising the following steps:

[0007] Step 1: Obtain the quantity of products to be produced according to the order number, obtain the quantity of raw materials according to the quantity of products to be produced, and set the threshold of the qualified completion rate of products under this quantity of raw materials as the standard threshold;

[0008] Step 2: Get the actual number of qualified products produced under the corresponding raw material quantity. The ratio of the actual number of qualified products produced to the number of products to be produced is the actual completion rate. Compare the actual completion rate with the standard threshold and make different response strategies based on the comparison results.

[0009] Step three: if the actual completion rate is less than the standard threshold, then carry out maintenance; if the actual completion rate is greater than or equal to the standard threshold, then obtain the number of unqualified products, which is the number of products that need to be re-produced to meet the order quantity.

[0010] In some embodiments, on the basis that the actual completion rate is greater than or equal to the standard threshold, the number of completed process steps of the unqualified product is obtained according to each unqualified product, and a threshold for the number of completed process steps is set. If the number of completed process steps of the unqualified product is less than the threshold for the number of completed process steps, it is marked as a defective product; if the number of completed process steps of the unqualified product is greater than or equal to the threshold for the number of completed process steps, it is marked as a repaired product, and different processing operations are performed on the repaired product and the defective product.

[0011] In some embodiments, for defective products, the raw materials required to re-produce the corresponding number of products are obtained based on the number of defective products, and the corresponding number of qualified products are re-produced based on the raw materials; for repaired products, the unfinished processes are obtained based on their completed processes, and the unfinished processes are completed to make them qualified products.

[0012] In some embodiments, for defective products, the specific processing method is: step one, obtain the number of unqualified products and set a threshold for the number of unqualified products; step two, obtain the number of defective products, compare the number of defective products with the threshold for the number of unqualified products, and make different response strategies according to the comparison results; for repaired products, obtain the unfinished process according to its completed process, complete the unfinished process to make it a qualified product.

[0013] In some embodiments, when the number of defective products is less than or equal to a threshold value of the number of unqualified products, the missing number of qualified products corresponding to the defective products are retrieved from the inventory; when the number of defective products is greater than the threshold value of the number of unqualified products, the missing number of qualified products corresponding to the defective products are re-produced.

[0014] In some implementations, when the actual completion rate is less than a standard threshold, the maintenance method is graded.

[0015] In some embodiments, when the actual completion rate is less than the standard threshold by less than 10%, it means that the degree below the threshold is small and it is marked as first-level maintenance; when the actual completion rate is less than the standard threshold by 10%-20%, it means that the degree below the threshold is moderate and it is marked as second-level maintenance; when the actual completion rate is less than the standard threshold by more than 20%, it means that the degree below the threshold is high and it is marked as third-level maintenance; different response methods are made for different maintenance levels.

[0016] In some embodiments, for level one maintenance, the system notifies the maintenance personnel to inspect the production line and perform routine maintenance; for level two maintenance, the system notifies the maintenance personnel to inspect important machines on the production line to identify and resolve problems with the important machines; for level three maintenance, the system notifies the maintenance personnel to inspect the entire production line to identify and resolve all problems on the production line.

[0017] In some embodiments, the order number is encoded in a 13-digit system, wherein the first eight digits represent the date, the middle four digits represent the quantity of the product to be produced, and the last digit is represented by a letter, and different letters represent different product models.

[0018] In some embodiments, the decoding of the order number is performed using Excel, and the specific steps are: step one, input the order number into a column of an Excel spreadsheet; step two, use the MID function to extract a specific portion of the string; step three, use the VALUE function to convert the extracted quantity portion into a numeric type; step four, use the IF or VLOOKUP function to map the product model letters to specific model names.

[0019] Compared with the prior art, the technical solution provided by the present invention has the following beneficial effects:

[0020] First, the present invention obtains the number of products to be produced through the order number, and the number of products to be produced reflects the number of raw materials required, and obtains the qualified products actually produced under the number of raw materials. The ratio of the actual qualified products produced to the number of products to be produced reflects the actual completion rate. The completion rate obtained in this way is more accurate than the completion rate obtained based on the process.

[0021] Secondly, in the present invention, by comparing the actual completion rate with the standard threshold, the problem of the production line can be discovered in time. If it is less than the standard threshold, it means that the qualified products produced cannot reach the minimum and need to be repaired. If it is greater than or equal to the standard threshold, the number of unqualified products and the number of processes that each unqualified product has completed are obtained. When the number of completed processes exceeds the threshold of the number of processes, it means that although the unqualified product is unqualified, it only needs to make up a few processes to reach the qualified product. When the number of completed processes is lower than the threshold of the number of processes, it means that the unqualified product has more missing processes. In this way, it can be reflected how many more products need to be produced to reach the order quantity. This reduces time and cost compared to directly producing the corresponding quantity of all unqualified products. At the same time, in this way, the method of directly producing all unqualified products can be filtered out to make the production of products more reasonable. For unqualified products, full consideration is given to whether they can still be used, rather than directly discarded, which saves more costs.

[0022] Third, for unqualified products that have completed fewer process steps than the threshold number of completed process steps, although they are defective products, by comparing them with the set threshold number of unqualified products, we can know the proportion of defective products to unqualified products. If the proportion is too large, only the corresponding number of products can be re-produced. However, if the proportion is not large, the corresponding number only needs to be transferred from the inventory, and then the repaired products can be completed to complete the process to complete the number of all products required for the order. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 Schematic diagram of the main steps of the method of the present invention;

[0024] Figure 2 Schematic diagram of the specific steps of the method of the present invention. DETAILED DESCRIPTION

[0025] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0026] It is to be understood that the term "one" should be understood as "at least one" or "one or more", that is, in one embodiment, the number of an element may be one, while in another embodiment, the number of the element may be multiple, and the term "one" should not be understood as a limitation on the quantity.

[0027] See also Figure 1 and Figure 2 The method for intelligent filtering of process plans and calculation of completion rate based on production order numbers provided by the present invention comprises the following steps:

[0028] First, the number of products to be produced is obtained according to the order number, and the specified number of raw materials is obtained according to the obtained number of products to be produced. In addition, normal production losses are formulated according to the factory production situation, and the qualified completion rate threshold X of the production products under the raw material quantity is set as the standard threshold. For example, 100 products are generated, 2 pieces are normally lost, and 98% is the qualified rate. This qualified rate is used as the standard threshold. For order numbers, enterprises usually encode them according to actual conditions. For example, the order number can be encoded in a 13-digit system, where the first eight digits represent the date, the middle four digits represent the number of products to be produced, and the last digit is represented by letters, and different letters represent different product models. Specifically, assuming that the order number is 202411130052A, the first eight digits are the year, month, and day, the middle four digits are the number of products to be produced, and the last letter represents the product model. The order number can be decoded in a variety of ways, such as using Excel. First, enter the order number into a column in an Excel spreadsheet. Second, use the MID function to extract a specific portion of the string. Next, use the VALUE function to convert the extracted quantity portion to a number. Finally, use the IF or VLOOKUP function to map the product model letters to specific model names.

[0029] Secondly, under the specified raw material quantity, the actual number of qualified products is obtained according to the actual production situation. The ratio of the actual number of qualified products to the number of products to be produced is the actual completion rate. Different response strategies are made according to the comparison between the actual completion rate and the standard threshold. For example, an order requires the production of 100 woks, and the specified raw material quantity is 150. Under the specified raw materials, the actual number of qualified woks produced is 90, so the actual completion rate is 90%.

[0030] Finally, the specific response strategy is: if the actual completion rate is less than the standard threshold, maintenance is required; if the actual completion rate is greater than or equal to the standard threshold, the number of unqualified products is obtained. In order to meet the total number of products required for the order, the corresponding number of products needs to be re-produced to make up for the missing number of unqualified products caused by the first production. In addition, the number of processes that each unqualified product has completed can be obtained based on each unqualified product. Set the threshold for the number of completed processes to M. If the number of processes that the unqualified product has completed is less than M, it is marked as a defective product. According to the number of defective products, the number of qualified products to be re-produced is obtained, and the raw materials are reused to produce the corresponding number of qualified products; if the number of processes that the unqualified product has completed is greater than or equal to M, it is marked as a repair product, and the repair product is subjected to the process completion operation. According to the above example, the qualified products required for the order are 100 pieces, and the qualified products produced under the specified raw materials are 90 pieces, and the unqualified products are 10 pieces. Assume that each product should have gone through 10 processes to become a qualified product, and the threshold M is set to 8 processes. Among these 10 unqualified products, those with less than 8 processes are marked, and the number of marks is the number to be re-produced. The reason for re-production is that these unqualified products have many missing processes, and it is better to re-produce them directly than to complete the processes. And those with more than or equal to 8 processes are marked as repaired products. Because they only need to go through 1-2 more processes to become qualified products, the unqualified products marked as repaired products can be turned into qualified products by completing the missing processes. In this way, the 100 products required for the order are completed on the basis of reducing the number of products that need to be re-produced and utilizing some unqualified products. Compared with reproducing 10 products to complete the order, it saves cost and time.

[0031] On the basis of the above, after marking the defective products and repaired products, it is also possible to choose whether to re-produce according to the ratio of defective products to unqualified products, that is, another method for handling defective products. The specific method is: first, obtain the number of unqualified products, and set the threshold of the number of unqualified products to V. Then, obtain the number of defective products, compare the number of defective products with the threshold V, analyze the proportion of the threshold V, and derive different coping strategies according to the comparison results. When the number of defective products is less than or equal to the threshold V, that is, the proportion of the number of defective products in the unqualified products is small, then the number of missing qualified products corresponding to the defective products can be directly transferred from the inventory without re-production. For repaired products, they are regarded as qualified products after completing the process. When the number of defective products is greater than the threshold V, that is, the proportion of the number of defective products in the unqualified products is large. In this case, for repaired products, they are still regarded as qualified products after completing the process. As for the number of missing qualified products corresponding to the defective products, re-production is carried out. For example, there are 20 unqualified products in total, and the threshold value V is 5. When the number of defective products is less than or equal to 5, the number of defective products is very small and can be directly transferred from the inventory. Then, the repair products can be completed after the process is completed to complete all orders. When the number of defective products is greater than 5, the quantity in the inventory may not be enough. Therefore, the number of missing qualified products corresponding to the defective products needs to be re-produced, and the repair products can still be completed after the process is completed. In this way, by comparing the number of defective products with the threshold value of the number of unqualified products, it can be analyzed whether the number of defective products is relatively large or small. If it is small, there is no need to re-produce, and this small number can be transferred from the inventory. If it is large, the inventory may not be enough, and this part of the missing quantity needs to be re-produced.

[0032] In addition, when the actual completion rate is less than the standard threshold, in order to further analyze the degree of completion, the maintenance degree can be graded. The specific method is: based on the fact that the actual completion rate is less than the standard threshold, it is defined that when the actual completion rate is less than the standard threshold by less than 10%, it means that the degree below the threshold is small, and it is marked as first-level maintenance. At the first-level maintenance level, the system notifies the maintenance personnel to conduct a general inspection of the production line and perform routine maintenance. The causes of these problems may be: 1. Temporary equipment failure: Some equipment or tools may have minor failures, but they do not affect the overall production. It may be some loose connections or worn small parts. 2. Shortage of material supply: Some key materials or parts are insufficient in a short period of time, resulting in a slight decrease in production speed. 3. Improper operation: Employees' operating errors or small deviations in the process flow. New employees may not be familiar with the process, resulting in a slight decrease in efficiency. When the actual completion rate is less than the standard threshold by 10%-20%, it means that the degree below the threshold is moderate, and it is marked as second-level maintenance. At the second-level maintenance level, the system notifies the maintenance personnel to inspect important machines on the production line to find and solve problems caused by important machines. These problems may be caused by: 1. Key equipment failure: An important equipment is unstable or has degraded performance. The equipment needs to be calibrated or some key parts need to be replaced. 2. Production process bottleneck: A certain process becomes slower than other processes, resulting in a decrease in overall production efficiency. It may be necessary to optimize the workflow or reallocate resources. 3. Quality issues: Quality issues of raw materials or intermediate products lead to rework or additional inspections. A detailed inspection of the supply chain or production process is required. When the actual completion rate is less than the standard threshold by more than 20%, it means that the degree of below the threshold is high and it is marked as level 3 maintenance. At the level 3 maintenance level, the system notifies the maintenance personnel to check the entire production line to find and solve all problems on the production line. These problems may be caused by: 1. Systematic equipment failure: Multiple equipment has problems or the overall system fails. It may be necessary to shut down for maintenance or even replace some equipment. 2. Staffing issues: Large-scale staff changes or absences have led to a significant decrease in production line efficiency. It is necessary to retrain employees or adjust shift configurations. 3. Process flow issues: There are major defects in the process flow design, resulting in production efficiency failing to meet the standards. It may be necessary to redesign the process or introduce new technologies. 4. Environmental factors: Changes in the external environment, such as power supply, temperature, and humidity, seriously affect production. It is necessary to adjust the production environment or the adaptability of the equipment.

[0033] For the above method, in general, first, the number of products to be produced is obtained through the order number, and the number of products to be produced reflects the number of raw materials required. The qualified products actually produced under the number of raw materials are obtained, and the ratio of the actual qualified products to the number of products to be produced reflects the actual completion rate. The completion rate obtained in this way is more accurate than the completion rate based on the process. Secondly, by comparing the actual completion rate with the standard threshold, the problem of the production line can be discovered in time. If it is less than the standard threshold, it means that the qualified products produced cannot reach the minimum limit and need to be repaired. If it is greater than or equal to the standard threshold, the number of unqualified products and the completed processes of each unqualified product are obtained. When the number of completed processes exceeds the threshold of the number of completed processes, it means that although the unqualified product is unqualified, it only needs to complete a few processes to reach the qualified product. When the number of completed processes is lower than the threshold of the number of completed processes, it means that the unqualified product is missing more processes. In this way, it can be reflected how many more products need to be produced to reach the order quantity. Compared with directly producing the corresponding number of all unqualified products, this reduces time and cost. Finally, for unqualified products that have completed fewer process steps than the threshold number of completed process steps, although they are defective products, by comparing them with the set threshold number of unqualified products, we can know the proportion of defective products to unqualified products. If the proportion is too large, only the corresponding number of products can be re-produced. However, if the proportion is not large, the corresponding number only needs to be transferred from the inventory, and then the repaired products can be completed to complete the process to complete the number of all products required for the order.

[0034] The embodiments disclosed in the present invention, the process described above with reference to the flowchart can be implemented as a computer software program. The embodiments disclosed in the present invention include a computer program product, which includes a computer program carried on a computer-readable medium, and the computer program contains a program code for executing the method shown in the flowchart. In such an embodiment, the computer program can be downloaded and installed from the network through the communication part, and / or installed from a removable medium. When the computer program is executed by the central processing unit, the above functions defined in the method of the present application are executed. It should be noted that the computer-readable medium mentioned above in the present application can be a computer-readable signal medium or a computer-readable storage medium or any combination of the above two. The computer-readable storage medium can be, for example, but not limited to, a system, device or device of an electrical, magnetic, optical, electromagnetic, infrared segment, or semiconductor, or any combination of the above. More specific examples of computer-readable storage media can include, but are not limited to: an electrical connection with one or more wire segments, a portable computer disk, a hard disk, a random access memory, a read-only memory, an erasable programmable read-only memory, an optical fiber, a portable compact disk read-only memory, an optical storage device, a magnetic storage device, or any suitable combination of the above. In the present application, a computer-readable storage medium may be any tangible medium containing or storing a program that can be used by or in combination with an instruction execution system, apparatus, or device. In the present application, a computer-readable signal medium may include a data signal propagated in a baseband or as part of a carrier wave, which carries a computer-readable program code. Such propagated data signals may take a variety of forms, including but not limited to electromagnetic signals, optical signals, or any suitable combination of the above. A computer-readable signal medium may also be any computer-readable medium other than a computer-readable storage medium, which may send, propagate, or transmit a program for use by or in combination with an instruction execution system, apparatus, or device. The program code contained on the computer-readable medium may be transmitted using any suitable medium, including but not limited to: wireless segments, wire segments, optical cables, RF, etc., or any suitable combination of the above.

[0035] The flow chart and block diagram in the accompanying drawings illustrate the possible architecture, function and operation of the system, method and computer program product according to various embodiments of the present invention. In this regard, each square box in the flow chart or block diagram can represent a module, a program segment or a part of a code, and the module, the program segment or a part of the code contains one or more executable instructions for realizing the specified logical function. It should also be noted that in some alternative implementations, the functions marked in the square box can also occur in a sequence different from that marked in the accompanying drawings. For example, two square boxes represented in succession can actually be executed substantially in parallel, and they can sometimes be executed in the opposite order, depending on the functions involved. It should also be noted that each square box in the block diagram and / or flow chart, and the combination of the square boxes in the block diagram and / or flow chart can be implemented with a dedicated hardware-based system that performs the specified function or operation, or can be implemented with a combination of dedicated hardware and computer instructions.

[0036] Those skilled in the art should understand that the above description is only a specific implementation mode of the present application, but the protection scope of the present application is not limited thereto. Any technician familiar with the technical field can easily think of changes or substitutions within the technical scope disclosed in the present application, which should be covered by the protection scope of the present application.

Claims

1. A method for intelligent filtering of process plans and calculation of completion rate based on production order numbers, characterized in that: The following steps are involved: Step 1: Obtain the quantity of products to be produced according to the order number, obtain the quantity of raw materials according to the quantity of products to be produced, and set the threshold of the qualified completion rate of products under this quantity of raw materials as the standard threshold; Step 2: Get the actual number of qualified products produced under the corresponding raw material quantity. The ratio of the actual number of qualified products produced to the number of products to be produced is the actual completion rate. Compare the actual completion rate with the standard threshold and make different response strategies based on the comparison results. Step three: if the actual completion rate is less than the standard threshold, then carry out maintenance; if the actual completion rate is greater than or equal to the standard threshold, then obtain the number of unqualified products, which is the number of products that need to be re-produced to meet the order quantity.

2. The method for intelligent filtering of process plans and calculation of completion rate based on production order numbers according to claim 1 is characterized in that: On the basis that the actual completion rate is greater than or equal to the standard threshold, the number of completed processes of each unqualified product is obtained, and a threshold for the number of completed processes is set. If the number of completed processes of an unqualified product is less than the threshold for the number of completed processes, it is marked as a defective product; if the number of completed processes of an unqualified product is greater than or equal to the threshold for the number of completed processes, it is marked as a repaired product, and different processing operations are performed on repaired products and defective products.

3. The method for intelligent filtering of process plans and calculation of completion rate based on production order numbers according to claim 2 is characterized in that: For defective products, the raw materials required to re-produce the corresponding number of products are obtained based on the number of defective products, and the corresponding number of qualified products are re-produced based on the raw materials; for repaired products, the unfinished processes are obtained based on their completed processes, and the unfinished processes are completed to make them qualified products.

4. The method for intelligent filtering of process plans and calculation of completion rate based on production order numbers according to claim 2 is characterized in that: For defective products, the specific processing method is as follows: Step 1, obtain the number of unqualified products and set a threshold for the number of unqualified products; Step 2, obtain the number of defective products, compare the number of defective products with the threshold for the number of unqualified products, and make different response strategies based on the comparison results; For repaired products, the unfinished processes are obtained based on their completed processes, and the unfinished processes are completed to make them qualified products.

5. The method for intelligent filtering of process plans and calculation of completion rate based on production order numbers according to claim 4 is characterized in that: When the number of defective products is less than or equal to the threshold of the number of unqualified products, the missing number of qualified products corresponding to the defective products are retrieved from the inventory; when the number of defective products is greater than the threshold of the number of unqualified products, the missing number of qualified products corresponding to the defective products are re-produced.

6. The method for intelligent filtering of process plans and calculation of completion rate based on production order numbers according to claim 1 is characterized in that: When the actual completion rate is less than the standard threshold, the maintenance method is graded.

7. The method for intelligent filtering of process plans and calculation of completion rate based on production order numbers according to claim 6 is characterized in that: When the actual completion rate is less than the standard threshold by less than 10%, it means that the rate is less than the threshold by a small margin and is marked as first-level maintenance; when the actual completion rate is less than the standard threshold by 10%-20%, it means that the rate is moderately less than the threshold and is marked as second-level maintenance; when the actual completion rate is less than the standard threshold by more than 20%, it means that the rate is highly less than the threshold and is marked as third-level maintenance; different responses are taken for different maintenance levels.

8. The method for intelligent filtering of process plans and calculation of completion rate based on production order numbers according to claim 7 is characterized in that: For level 1 maintenance, the system notifies maintenance personnel to inspect the production line and perform routine maintenance; For level 2 maintenance, the system notifies maintenance personnel to inspect important machines on the production line to identify and resolve problems with the important machines; for level 3 maintenance, the system notifies maintenance personnel to inspect the entire production line to identify and resolve all problems on the production line.

9. The method for intelligent filtering of process plans and calculation of completion rate based on production order numbers according to claim 1 is characterized in that: The order number is coded in a thirteen-digit system, where the first eight digits represent the date, the middle four digits represent the quantity of products to be produced, and the last digit is represented by a letter, with different letters representing different product models.

10. The method for intelligent filtering of process plans and calculation of completion rate based on production order numbers according to claim 9 is characterized in that: The decoding of the order number is done using Excel, and the specific steps are: Step 1, enter the order number into a column in the Excel table; Step 2, use the MID function to extract the specific part of the string; Step 3, use the VALUE function to convert the extracted quantity part to a numeric type; Step 4, use the IF or VLOOKUP function to map the product model letters to the specific model names.

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